Fan duct and Mini Differential IR sensor mount for E3Dv6 hot end with commonly used mounting plate

prusaprinters

I made the original fan duct to fit a delta - but then I decided that I didn't like deltas! I then made some modifications so that it would fit my existing Prusa i3 and a new recently built CoreXY. This meant changing the mounting plate from "Kossel effector" to "standard 50mm spaced M4 holes", as found under a Gregs' Wade Extruder (and also used on many printers). I also increased the diameter of the fan hole slightly to reduce air resistance. The main reason for using this mount is that I wanted to use dc42's IR sensor, with the bonus of getting rid of the original E3Dv6 cooling fan mount, which I consider the only weak part of the design (mine always got loose, and rattled around). I have included the files for 2 types of duct - one for the v1.0 version of the IR sensor, and the other for the smaller v1.1 version. Note that I mount the sensor's PCB on the front of the mounting lugs instead of the back as originally designed; this is to move the board a bit further away from the hot-end. In addition I mounted a thin sheet of stainless steel (wrapped in kapton tape) on the back of the lugs as an extra heat deflector. I have also included files for a spacer plate, but that is only required if you want to fit the fan mount to a G&C CoreXY printer (http://www.thingiverse.com/thing:1003119). Apologies for the poor pictures of this piece - it's very hard to get a good one when it's mounted on a printer, surrounded by lots of bits and pieces! Many thanks to the original designers of this mount - my modifications are trivial compared to their work! Print Settings Printer: Prusa i3 Rafts: Doesn't Matter Supports: Yes Resolution: 0.2 or 0.3 Infill: 30% - 40% Notes: I printed mine using ABS, with the mount plate downwards (I used a brim). It is fairly easy to remove the support which, in my prints, only appeared in the fan chamber. The E3Dv6 is a VERY tight fit on the mounting plate - I had to scrape the plastic a bit before I could slide the hot-end fully into the slot. It's best to maintain a tight fit, to avoid any wobble. You should be able to mount the 40mm fan using M3 screws (don't drill out the holes before fitting). Note that you will still need something above this part to locate the top of the E3Dv6, just as with any other mounting plate. This may be the bottom of the extruder, or some part of the X carriage bracket. Category: 3D Printer Parts